width MITSUBISHI MONTERO 1991 Service Manual

CYLINDER HEAD SPECIFICATIONS (SOHC)
CYLINDER HEAD TABLE (SOHC)








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Application Specification
Cylinder Head Height ................... 3.307" (84.00 mm)
Maximum Warpage ........................... .008" (.20 mm)
Valve Seats (Intake & Exhaust)
Seat Angle ......................................... 45

Seat Width .................... .035-.051" (.90-1.30 mm)
Seat Bore Diameter ....... 1.732-1.742" (44.00-44.25 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide Length ..................... 1.732" (44 mm)
Stem-To-Guide Clearance
Standard ................ .0012-.0024" (.030-.060 mm)
Limit ................................ .004" (.10 mm)
Exhaust Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide Length ..................... 1.890" (48 mm)
Stem-To-Guide Clearance
Standard ................ .0020-.0035" (.050-.090 mm)
Limit ................................ .006" (.15 mm)









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CYLINDER HEAD SPECIFICATIONS (DOHC)
CYLINDER HEAD TABLE (DOHC)








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Application Specification
Cylinder Head Height .................... 5.20" (132.1 mm)
Maximum Warpage ........................... .008" (.20 mm)
Valve Seats (Intake & Exhaust)
Seat Angle ......................................... 45

Seat Width .................... .035-.051" (.90-1.30 mm)
Seat Bore Diameter ....... 1.417-1.427" (35.99-36.25 mm)
Valve Guides
Intake Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide
Installed Height ................... .689" (17.50 mm)
Stem-To-Guide Clearance
Standard ................ .0008-.0020" (.020-.051 mm)
Limit .............................. .0039" (.099 mm)
Exhaust Valve
Valve Guide Cylinder Head
Bore I.D. ............. .5118-.5189" (13.00-13.18 mm)
Valve Guide
Installed Height ................... .689" (17.50 mm)
Valve Stem-To-Guide
Clearance
Standard ............... .0020-.0035" (.051-.089 mm)
Limit ............................. .0047" (.119 mm)









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CAMSHAFT SPECIFICATIONS (SOHC)

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AN TI- L O CK B RAK E S A FE TY P R EC AU TIO NS

1991 M it s u bis h i M onte ro
GENERAL INFORMATION
Anti-Lock Brake Safety Precautions
* PLEASE READ THIS FIRST *
This article is intended for general information purposes
only. This information may not apply to all makes and models. If
vehicle is equipped with Anti-Lock Brake System (ABS), refer to
appropriate ANTI-LOCK BRAKE SYSTEM article in the BRAKES section for
description, operation, depressurizing, testing, system bleeding,
trouble shooting and servicing of specific system.
WARNING: Failure to depressurize ABS could lead to physical injury.
ANTI-LOCK BRAKE SAFETY PRECAUTIONS
WARNING: Failure to depressurize ABS could lead to physical injury.
* NEVER open a bleeder valve or loosen a hydraulic line
while ABS is pressurized.
* NEVER disconnect or reconnect any electrical connectors
while ignition is on. Damage to ABS control unit may result.
* DO NOT attempt to bleed hyudarulic system without first
referring to the appropriate ANTI-LOCK BRAKE SYSTEM article
in the BRAKES section.
* Only use specially designed brake hoses/lines on ABS equipped
vehicles.
* DO NOT tap on speed sensor components (sensor, sensor rings).
Sensor rings must be pressed into hubs, NOT hammered into
hubs. Striking these components can cause demagnetization or
a loss of polarization, affecting the accuracy of the speed
signal returning to the ABS control unit.
* DO NOT mix tire sizes. Increasing the width, as long as tires
remain close to the original diameter, is acceptable. Rolling
diameter must be identical for all 4 tires. Some
manufacturers recommend tires of the same brand, style and
type. Failure to follow this precaution may cause inaccurate
wheel speed readings.
* DO NOT contaminate speed sensor components with grease. Only
use recommended coating, when system calls for an
anti-corrosion coating.
* When speed sensor components have been removed, ALWAYS check
sensor-to-ring air gaps when applicable. These specifications
can be found in each appropriate article.
* ONLY use rocommended brake fluids. DO NOT use silicone brake
fluids in an ABS equipped vehicle.
* When instlling transmittion devices (CB's, telephones, etc.)
on ABS equipped vehicles, DO NOT locate the antenna near the
ABS control unit (or any control unit).
* Disconnect all on-board computers, when using electric
welding equipment.
* DO NOT expose the ABS control unit to prolonged periods of
high heat (185
F/85C for 2 hours is generally considered a
maximum limit).

Fig. 13: Exploded View of Master Cylinder (Typical)
Courtesy of Mitsubishi Motor Sales of America.
DISC BRAKE SPECIFICATIONS
DISC BRAKE SPECIFICATIONS TABLE








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Application In. (mm)
Disc Diameter
Montero
2.6L ...................................... 10.2 (259)
3.0L ...................................... 10.9 (277)
Pickup & Ram-50
2WD ....................................... 10.2 (259)
4WD ....................................... 10.9 (277)
Lateral Runout ................................ .006 (.15)
Parallelism .......................................... ( 1)
Original Thickness .............................. .87 (22)
Master Cylinder Diameter .................... .938 (23.83)
Minimum Refinish Thickness .................... .80 (20.4)
Discard Thickness ............................. .78 (19.8)
( 1) - Information is not available.









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DRUM BRAKE SPECIFICATIONS
DRUM BRAKE SPECIFICATIONS TABLE








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Application In. (mm)
Drum Diameter ................................. 10.0 (254)
Drum Width ........................................... ( 1)
Master Cylinder Diameter .................... .938 (23.83)

gear. Securely stake pin in 2 places. Ensure adhesive is removed from
ring gear mounting bolts and gear mounting surface. Clean internal
threads with tap.
5) Ensure alignment marks on differential case and ring gear
are aligned. Apply Loctite 271 to bolts and install ring gear on
differential case. Tighten bolts in diagonal sequence to
specification. See TORQUE SPECIFICATIONS table at the end of this
article.
CASE ASSEMBLY (LIMITED SLIP)
1) Assemble 2 friction discs and 2 friction plates; assemble
plate, disc, plate and disc. Measure assembly thickness. Assemble
discs and plates to give standard difference of .002" (.05 mm) between\
the 2 sides.
2) Assemble spring plates and spring discs with one on each
side. Measure assembly thickness. Assemble disc and plates to obtain
minimum difference in thickness between each assembly.
3) Assemble clutch assemblies, pressure rings, pinion gears,
side gears and pinion shaft. Measure overall width of assembly plus
spring plates and spring discs. This measurement is "C". See Fig. 6.
Fig. 6: Measuring Clutch Assembly Width
Courtesy of Chrysler Motors.
4) Determine depth "D" of differential case, using formula
"D"="E"+"F"-"G" or "D"="E"+"H"-"F"-"G" . See Fig. 7. Subtract
measurement "C" from measurement "D" to determine spring plate-to-case

clearance. Adjust spring disc thickness to obtain proper spring plate-
to-case clearance. Correct clearance is .0024-.0079" (.060-.200 mm).
Fig. 7: Measuring Limited Slip Case Depth (Montero 3.0L & Pickup)
Courtesy of Chrysler Motors.
CAUTION: DO NOT interchange clutch components for right and left
sides. Mark clutch components for location.
5) Remove spring plates, spring discs, friction plates and
friction disc from pressure rings. Mark components for location.
Install thrust washers on each end of pressure rings. See Fig. 8.
6) Measure distance from end of thrust washer to rear face of
pressure ring. Select proper thickness thrust washers to obtain a .
002" (.05 mm) or less difference between measurements.
7) Once correct thrust washers are determined, install thrust
washers on pressure rings. Squeeze pressure rings together and measure
width from end of thrust washer to remaining thrust washer. This is
dimension "H". See Fig. 8.
8) Determine distance between thrust washer surfaces when
differential case is assembled. This is dimension "I"
("I"="J"+"K"+"L"). See Fig. 8. Dimension "J" is the same as dimension
"D" in step 4).

remote vacuum regulator. The internal solenoid is normally open, which
causes the vacuum signal to be vented off to the atmosphere when EGR
is not controlled by the Electronic Control Module (ECM). The solenoid\
valve opens and closes the vacuum signal, controlling the amount of
vacuum applied to the diaphragm. See Fig. 12.
The electronic EGR valve contains a voltage regulator, which
converts ECM signal and regulates current to the solenoid. The ECM
controls EGR flow with a pulse width modulated signal based on
airflow, TPS and RPM. This system also contains a pintle position
sensor, which works similarly to a TPS sensor. As EGR flow is
increased, the sensor output increases.
Verify EGR valve is present and not modified or purposely
damaged. Ensure thermal vacuum switches, pressure transducers, speed
switches, etc., (if applicable) are not by-passed or modified. Ensure
electrical connector to EGR valve is not disconnected.
Fig. 12: Cutaway View Of Typical Integrated Electronic EGR Valve
Courtesy of General Motors Corp.
SPARK CONTROLS (SPK)

during manufacture, some new type valves cannot be reground.
Resurface valve on proper angle specification using valve
grinding machine. Follow manufacturer's instructions for valve
grinding machine. Specifications may indicate a different valve face
angle than seat angle.
Measure valve margin after grinding. Replace valve if not
within specification. Valve stem tip can be refinished using valve
grinding machine.
Valve Lapping
During valve lapping of recent designed valves, be sure to
follow manufacturers recommendations. Surface hardening and materials
used with some valves do not permit lapping. Lapping process will
remove excessive amounts of the hardened surface.
Valve lapping is done to ensure adequate sealing between
valve face and seat. Use either a hand drill or lapping stick with
suction cup attached.
Moisten and attach suction cup to valve. Lubricate valve stem
and guide. Apply a thin coat of fine valve grinding compound between
valve and seat. Rotate lapping tool between the palms or with hand
drill.
Lift valve upward off the seat and change position often.
This is done to prevent grooving of valve seat. Lap valve until a
smooth polished seat is obtained. Thoroughly clean grinding compound
from components. Valve to valve seat concentricity should be checked.
See VALVE SEAT CONCENTRICITY.
CAUTION: Valve guides must be in good condition and free of carbon
deposits prior to valve seat grinding. Some engines contain
an induction hardened valve seat. Excessive material removal
will damage valve seats.
Valve Seat Grinding
Select coarse stone of correct size and angle for seat to be
ground. Ensure stone is true and has a smooth surface. Select correct
size pilot for valve guide dimension. Install pilot in valve guide.
Lightly lubricate pilot shaft. Install stone on pilot. Move stone off
and on the seat approximately 2 times per second during grinding
operation.
Select a fine stone to finish grinding operation. Grinding
stones with 30 and 60 degree angles are used to center and narrow the
valve seat as required. See Fig. 10.
Fig. 10: Adjusting Valve Seat Width - Typical
This Graphic For General Information Only
Valve Seat Replacement
Replacement of valve seat inserts is done by cutting out

Fig. 18: Measuring Connecting Rod Side Clearance - Typical
This Graphic For General Information Only
Check for improper bearing installation, wrong bearing cap
or insufficient bearing clearance if side clearance is insufficient.
Connecting rod may require machining to obtain proper clearance.
Excessive clearance usually indicates excessive wear at crankshaft.
Crankshaft must be repaired or replaced.
MAIN & CONNECTING ROD BEARING CLEARANCE
Plastigage Method
Plastigage method may be used to determine bearing clearance.
Plastigage can be used with an engine in service or during reassembly.
Plastigage material is oil soluble.
Ensure journals and bearings are free of oil or solvent.
Oil or solvent will dissolve material and false reading will be
obtained. Install small piece of Plastigage along full length of
bearing journal. Install bearing cap in original location. Tighten
bolts to specification.
CAUTION: DO NOT rotate crankshaft while Plastigage is installed.
Bearing clearance will not be obtained if crankshaft is
rotated.
Remove bearing cap. Compare Plastigage width with scale on
Plastigage container to determine bearing clearance. See Fig. 19.
Rotate crankshaft 90 degrees. Repeat procedure. this is done to check
journal eccentricity. This procedure can be used to check oil
clearance on both connecting rod and main bearings.

CYLINDER BLOCK
* PLEASE READ THIS FIRST *
NOTE: Always refer to appropriate engine overhaul article in the
ENGINES section for complete overhaul procedures and
specifications for the vehicle being repaired.
BLOCK CLEANING
Only cast cylinder blocks should be hot tank cleaned.
Aluminum cylinder blocks should be cleaned using cold tank method.
Cylinder block is cleaned in order to remove carbon deposits, gasket
residue and water jacket scale. Remove oil galley plugs, freeze plugs
and cam bearings prior to block cleaning.
BLOCK INSPECTION
Visually inspect the block. Check suspected areas for cracks
using the Dye Penetrant inspection method. Block may be checked for
cracks using the Magnaflux method.
Cracks are most commonly found at the bottom of the
cylinders, the main bearing saddles, near expansion plugs and between
the cylinders and water jackets. Inspect lifter bores for damage.
Inspect all head bolt holes for damaged threads. Threads should be
cleaned using tap to ensure proper head bolt torque. Consult machine
shop concerning possible welding and machining (if required).
CYLINDER BORE INSPECTION
Inspect the bore for scuffing or roughness. Cylinder bore
is dimensionally checked for out-of-round and taper using dial bore
gauge. For determining out-of-round, measure cylinder parallel and
perpendicular to the block centerline. Difference in the 2 readings
is the bore out-of-round. Cylinder bore must be checked at top, middle
and bottom of piston travel area.
Bore taper is obtained by measuring bore at the top and
bottom. If wear has exceeded allowable limits, block must be honed
or bored to next available oversize piston dimension.
CYLINDER HONING
Cylinder must be properly honed to allow new piston rings to
properly seat. Cross-hatching at correct angle and depth is critical
to lubrication of cylinder walls and pistons.
A flexible drive hone and power drill are commonly used.
Drive hone must be lubricated during operation. Mix equal parts of
kerosene and SAE 20w engine oil for lubrication.
Apply lubrication to cylinder wall. Operate cylinder hone
from top to bottom of cylinder using even strokes to produce 45 degree
cross-hatch pattern on the cylinder wall. DO NOT allow cylinder hone
to extend below cylinder during operation.
Recheck bore dimension after final honing. Wash cylinder
wall with hot soapy water to remove abrasive particles. Blow dry with
compressed air. Coat cleaned cylinder walls with lubricating oil.
DECK WARPAGE
Check deck for damage or warped head sealing surface. Place
a straightedge across gasket surface of the deck. Using feeler gauge,
measure clearance at center of straightedge. Measure across width and

WARNING: Avoid breathing R-134a refrigerant and PAG lubricant vapors,
exposure may irritate eyes, nose and throat. To remove
R-134a from system use R-134a recycling equipment that meets
SAE J2210 specifications. If accidental system discharge
occurs, ventilate work area before resuming service.
ANTI-LOCK BRAKE SYSTEM
The anti-lock brake system contains electronic equipment that
can be susceptible to interference caused by improperly installed or
high output radio transmitting equipment. Since this interference
could cause the possible loss of the anti-lock braking capability,
such equipment should be installed by qualified professionals.
On models equipped with anti-lock brake systems, ALWAYS
observe the following cautions:
* DO NOT attempt to bleed hydraulic system without first
referring to the appropriate ANTI-LOCK BRAKE SYSTEM article
in the BRAKES Section.
* DO NOT mix tire sizes. As long as tires remain close to the
original diameter, increasing the width is acceptable.
Rolling diameter must be identical for all 4 tires. Some
manufacturers recommend tires of the same brand, style and
type. Failure to follow this precaution may cause inaccurate
wheel speed readings.
* Use ONLY recommended brake fluids. DO NOT use silicone brake
fluids in an ABS-equipped vehicle.
REPLACING BLOWN FUSES
Before replacing a blown fuse, remove ignition key, turn off
all lights and accessories to avoid damaging the electrical system. Be
sure to use fuse with the correct indicated amperage rating. The use
of an incorrect amperage rating fuse may result in a dangerous
electrical system overload.
BATTERY WARNING
WARNING: When battery is disconnected, vehicles equipped with
computers may lose memory data. When battery power is
restored, driveability problems may exist on some vehicles.
These vehicles may require a relearn procedure. See
appropriate COMPUTER RELEARN PROCEDURES article in the
GENERAL INFORMATION section below.
BRAKE FLUID
For vehicles equipped with a traction control system, idle
engine while pouring brake fluid into reservoir.
CATALYTIC CONVERTER
Continued operation of vehicle with a severe malfunction
could cause converter to overheat, resulting in possible damage to
converter and vehicle.
ELECTROSTATIC DISCHARGE SENSITIVE (ESD) PARTS
WARNING: Many solid state electrical components can be damaged by
static electricity (ESD). Some will display a warning label,
but many will not. Discharge personal static electricity by